Wittke StarLight User manual

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Maintenance Manual

10/19/07 PART NUMBER: #90309
STARLIGHT™ & SUPERDUTY™
MAINTENANCE MANUAL

Part #: 90309 iii
Table of Contents
Maintenance
Liability ..................................................................................................... 1
Warning .................................................................................................... 1
Lifting Components for Service ............................................................. 1
Lifting the Arms and Forks ........................................................ 2
Lifting the Front Body ................................................................ 2
Lifting the Entire Body ............................................................... 4
Prior to Hydraulic System Maintenance ................................................ 6
Hydraulic Settings and materials ........................................................... 7
System Settings: ....................................................................... 7
Welding Information ................................................................................ 7
Lubrication ............................................................................................... 8
Centralized Grease Block ......................................................... 9
Packer Rails Lubrication ......................................................... 10
Maintenance Checklist .......................................................................... 11
Electrical System ................................................................................... 34
Electrical Schematics .............................................................. 34
How the Electrical System Works ........................................... 34
Control Panel (located centrally in the cab) ................................ 34
Relay Box (located in the cab) .................................................... 35
Electronic Controller .................................................................... 35
Proximity Switches ...................................................................... 36
Harnesses ................................................................................... 36

iv Part #: 90309
Adjusting and Repairing Electrical Components ............................... 36
Circuit Breakers and Fuses ..................................................... 37
Fuses .......................................................................................... 37
Manual Reset Circuit Breakers ................................................... 37
Adjusting the Proximity/Limit Switch Settings ......................... 39
Proximity Switches on the Street Side ........................................ 40
Proximity Switches on the Curb Side .......................................... 40
Lever Arm Limit Switches ....................................................... 41
Proximity Switch Gap Adjustment ........................................... 41
Packer Fully Retracted Proximity Switch ................................ 42
Packer Fully Extended Proximity Switch ................................. 43
Side Access Door Limit Switch ............................................... 45
Top Door Fully Open Proximity Switch ................................... 46
Tailgate Unlocked Proximity Switch ........................................ 46
Tailgate Fully Open Proximity Switch ..................................... 47
Arms Partially Raised Proximity Switch .................................. 47
Arms and Forks Fully Retracted Proximity Switch ................. 50
Body Raised Limit Switch (optional) ....................................... 53
Pneumatic System ................................................................................ 54
How the Pneumatic System Works ......................................... 54
Air supply .................................................................................... 54
Filter System ............................................................................... 54
In-Line Lubricator (optional) ........................................................ 55
Controls ....................................................................................... 55
Outside Controls ......................................................................... 55

Part #: 90309 v
Valve Box and Air Valves ............................................................ 56
Air Actuators ............................................................................... 57
Central Air Drain Cocks (optional) .............................................. 57
Pneumatic System Schematics .............................................. 58
Hydraulic System .................................................................................. 60
Hydraulic Oil Tank ................................................................... 60
Return Line Filter .................................................................... 61
Return Line Filter element ....................................................... 61
Routine Maintenance .............................................................. 61
Element Replacement Procedure ........................................... 62
Hydraulic Oil ............................................................................ 63
Recommended Lubricant ............................................................ 63
Hydraulic Pump ....................................................................... 63
Directional Control Valve ........................................................ 64
Pressure Relief Valve ............................................................. 64
Work Circuits ........................................................................... 65
Arms Up Deceleration Valve ................................................... 65
Pack Circuit Dump Valve ........................................................ 67
Pressure Switch ...................................................................... 67
Pressure Switch Adjustment ....................................................... 67
Timer Adjustment ........................................................................ 68
Tailgate Lock Valve ................................................................. 70
Service Hoist (optional) ........................................................... 71
Arms Down Work Section ....................................................... 72

vi Part #: 90309
Arms Down Deceleration Valve (optional) .............................. 72
Main System Pressure Adjustment ......................................... 74
Commercial Front Loader ........................................................... 74
Hydraulic Hose ........................................................................ 75
Hydraulic System Schematics ................................................ 76
Packer Maintenance .............................................................................. 80
Packer Wear Plates Replacement .......................................... 80
Body Guide Wear Plates Replacement .................................. 82
Packer Removal Procedure .................................................... 84
Packer Cylinder Replacement ................................................ 85

Part #: 90309 1
MAINTENANCE
LIABILITY
Labrie Environmental Group assumes no liability for any
incidental, consequential or other liability from the use of this
information. All risks and damages, incidental or otherwise,
arising from use or misuse of the information contained herein
are entirely the responsibility of the user. Although careful
precaution has been taken in the preparation of this material, we
assume no responsibility for errors or omissions.
WARNING
Prior to using your new STARLIGHT™ or SUPERDUTY™ Front
Loader, it MUST BE COMPLETELY LUBRICATED as shown on
the lube decal located near the rear of the body on the
passenger side. (Also see Lubrication section in the
Maintenance Checklist).
Initial lubrication carried out by Labrie Environmental Group is
sufficient for production and transport purposes ONLY!
With your safety in mind, we would like to remind you that ONLY
QUALIFIED PERSONNEL should service the hydraulic,
electrical, and pneumatic systems on your refuse vehicle. In
addition, these mechanics should be fully versed in the
operation of this unit. Please read the Operator Manual, prior to
attempting any maintenance of your Wittke Front Loader.
LIFTING COMPONENTS FOR SERVICE
Lifting components of the WITTKE requires special attention to
safety.
Before attempting these lifts:
•Emptythebody.
• Chock both the front and rear wheels.
•Standclearofanycranesorsimilarliftingdevices
when doing any lifts.
•Donotstandorwalkunderaloadthatissuspended
unless there are additional safety blocking devices
in place.

2Part #: 90309
While Labrie Environmental Group has included the
specifications of the lift equipment we use, these specifications
are intended as guides only. It is your responsability to ensure
your lift equipment meets all safety standards and that only
qualified personnel attempt these lifts.
LIFTING THE ARMS AND FORKS
You may need to lift the arms and forks manually. If you need to
do this, remember:
• If the forks cylinders are removed or disconnected,
the forks can rotate freely – tie each fork to the arms
before lifting the arms and forks assembly.
•Placealiftslingratedto6400lbs(2903kgs)inthe
middle of the fork pivot tube.
• Complete job, reconnect.
• Keep the sling in place while you repressurize the
system.
LIFTING THE FRONT BODY
Lifting the front body may be required when you need to
complete repairs.
You will need:
• A 18000-lb (8165 kgs) overhead crane
•Twoliftslingsratedto6000lbs(2722kgs)
• A 12000-lb (5443 kgs) lift beam
To raise the front body:
1. Raise the arms until they are resting on the rubber arm
stops on the sides of the body (stowed position) and
completely retract the forks against the arms.
CAUTION
IFBOTH ARM CYLINDERS ARE REPLACED, MOVE THE JOYSTICK BACK
AND FORTH IN GRADUALLY INCREASING INCREMENTS. THIS WILL
DISTRIBUTE THE OIL EVENLY WITHIN THE CYLINDERS AND PREVENT
THE ARMS FROM FALLING.